1 Graphic Products Industrial PracticesThese icons indicate that teacher’s notes or useful web addresses are available in the Notes Page. This icon indicates that the slide contains activities created in Flash. These activities are not editable. For more detailed instructions, see the Getting Started presentation. 1 of 31 © Boardworks Ltd 2005
2 Learning objectives Learning objectives To learn about:different methods of production scales of production graphic products investigations CAD and CAM in industry jigs, moulds, formers, templates barcodes waste reduction. Learning objectives 2 of 31 © Boardworks Ltd 2005
3 Production types There are five main types of production, these are:One-off production Batch production Mass production Just-in-time production Continuous production Picture complements of Printing Industry Exchange Printing Industry Exchange is a resource, connecting print buyers with printing companies 24/7. FREE printing quote request submittals in connecting direct to many of the best print manufactures both domestic & international ... Many production processes involve a mixture of these methods. Some parts and components can be mass produced, while other parts may need to be individually made.
4 One-off production One-off production is used when only one item is required. One-off products are often hand-made and designed and manufactured for a very specific need or person. One-off production usually takes a long time and is very labour intensive. This means that the outcome is often expensive. Advantages Disadvantages Product made to exact client specifications. Labour intensive. Labour often must be highly skilled. Materials expensive because they are bought in small quantities. Little investment needed. High design and manufacturing costs.
5 Batch production Batch production is used when a set number of products are needed. One batch can consist of ten items or thousands of items, depending on the requirements of the project. Flexible manufacturing systems are used – these involve production lines that can be altered to produce different items. The production line is set up for each new batch. Once a batch is finished, it can be altered for the next product. Advantages Disadvantages Specialization of tasks is possible, increasing efficiency. If you produce too few items, it can cost a lot to set up the equipment again for another batch later. Quick response to customer needs. Machines can be reset and used to produce other products. Production has to stop while production lines are reset.
6 Mass production Mass production makes products on a large scale. It can involve the production of millions of units. It sometimes involves continuous production techniques. Mass production usually leads to lower production costs because materials can be bought in bulk, and tasks can be specialized. Advantages Disadvantages Specialization – production is split into stages and specific labour matched. Social implications – sometimes the jobs can get boring and don’t require much skill. Workers simply look after a machine. Often highly mechanized, so production is fast and labour costs are low. Bulk material buying means lower costs. Initial set up costs can be very high.
7 Continuous productionThis is when manufacturing takes place 24 hours a day, 7 days a week. It is sometimes known as 24/7 production or continuous flow production. It is most commonly used for mass production. Most tasks are usually carried out by computers and machines. The few workers that are needed operate in shifts, so that production is not interrupted. Advantages Disadvantages Uninterrupted manufacture so goods are produced quickly. Initial set up costs can be very high. Fewer workers, so lower labour costs. Workers often must be paid more for working at night. No time and money wasted in starting, stopping and resetting machines. Social implications – sometimes the jobs can get boring and don’t require much skill.
8 Just-in-time productionJust-in-time is a tightly organized control system that aims to ensure that materials and components arrive at the factory at the exact time they are needed. This reduces storage and wastage costs and should eliminate the possibility of running out of materials. It uses stock management to ensure that materials are available when needed. Advantages Disadvantages Production is more flexible as there are no large stockpiles of materials. If supply fails, the production line will just stop. Relies heavily on suppliers and couriers being punctual. Storage costs are very small.
9 First, you must decide how many products you are going to need.Scales of production When you are designing a product, you must think how it will be made. First, you must decide how many products you are going to need. The cost of producing each unit is usually lower the more you make, but you will waste money if you make more than you can use or sell. The number of units you choose to make will help you decide whether to: produce your product as a one-off produce your product in batches mass produce your product.
10 Scales of production
11 Graphic product investigationsThree of the most common graphic products are packaging, newspapers and posters. You need to be familiar with how these products are manufactured. The next few slides will explore how these products are manufactured from the raw materials to the finished products.
12 Graphic product investigation – packagingOnce the research and development stages are complete, the net design will be drawn on a computer using computer aided design and linked to a printer. The package will then be printed. The most common printing method used for packaging is lithography. It produces good print quality and is reasonably fast and cheap. As soon as the ink is dry, the net will be spirit varnished. Glue will be added to the joining tabs and the net assembled. The net will then be cut out using a die cutter. The net will then be scored and folded using a folding machine.
13 Graphic product investigation – newspapersThe text is written and arranged with any images, using a desktop publishing package. The template remains the same, but the information changes daily. The computer is linked to the lithography printer. The newspapers are then printed using lithography. The pages are cut using a guillotine. The paper is then folded using a bending machine.
14 Graphic product investigation – postersThe design is either drawn on a computer using computer aided design, or transferred onto computer using an input device, such as a scanner. The computer is linked to a printer. The most common printing method used for posters is lithography. Lithography produces good quality prints, is reasonably cheap and lends itself well to mass production methods. The poster will then be spirit varnished. This will happen as soon as the ink is dry. It gives the poster a glossy finish.
15 COMPUTER AIDED MANUFACTURECAD and CAM systems Computer Aided Design and Computer Aided Manufacture are terms used for a range of different ICT applications that can help in the design and manufacture of products. COMPUTER AIDED DESIGN A computer aided system for creating, developing, modifying and communicating design ideas. COMPUTER AIDED MANUFACTURE A term used for manufacturing processes controlled by computers.
16 CAD and CAM Computer aided design is widely used in industry. It allows you to: draw with great accuracy, scale drawings when needed and duplicate images easily generate 3D images view a design from any angle generate working drawing from presentation images render products to look exactly as you would like them.
17 CAD and CAM Computer aided manufacture is also used extensively in industry. Computers control hi-tech machines and robotics that can manufacture products with great speed and accuracy. CAM devices include: Routers – These are computer controlled milling machines. They can create 3D and rotational objects from blocks of material. Cutters/plotters – A vinyl cutter/plotter can be programmed to draw or cut out text and images accurately. Images courtesy of Techsoft (www.techsoftuk.co.uk). Solid laser plotters (stereolithography)– A new range of 3D printers that can create products by building up layers.
18 CAD and CAM The video clip below shows how labels for sandwich packaging are designed on computer, and then cut out using a computer controlled vinyl cutter. Video courtesy of Techsoft (www.techsoftuk.co.uk).
19 Guard bars separate numbersBarcodes Barcodes consist of a series of vertical lines of different widths, which correspond to numbers. They are now printed on most products. Barcodes contain information about the product. They are read by an optical scanner. Manufacturer code Product code Guard bars separate numbers The scanner sends a laser beam over the barcode. The bars are detected because they reflect less light back. The scanner transmits the code to the in-store computer, which then relays the product description and price back to the checkout.
20 Jigs, moulds, formers and templatesJigs, moulds and formers are used by manufacturers to make the same object repeatedly and identically. Jigs help you to line objects up. Moulds help you to form objects by surrounding and shaping them. Formers help you to bend and shape objects accurately and consistently. This ice cube tray is a mould. It allows you to make ice cubes that are all the same size and shape over and over again.
21 Jigs, moulds, formers and templatesThis mould is used to manufacture a hand held drum. You can see that it has been split into two parts to allow the drum to be removed once it has been moulded. This jig allows holes to be drilled in a sheet of material in exactly the same places every time.
22 Jigs, moulds, formers and templatesFormers are a bit like the opposite of moulds – instead of placing the material to be shaped inside, you bend or shape the material around the former. Here are two examples: You can make a papier mâché sphere by pasting newspaper to a balloon. The balloon acts as a former. Once the papier mâché is dry, the balloon can be burst and removed. A former can be used to bend a metal rod into a particular shape.
23 Jigs, moulds, formers and templatesYou will find that you use a lot of templates in graphic products. Templates allow you to replicate designs over and over again, with great accuracy. These are french curve templates – you can use them to help you draw lots of different curves. This template helps you draw letters.
24 Jigs, moulds, formers and templatesYou also get templates within desk top publishing (DTP) packages. These are graphical templates for producing a variety of standard documents such as CVs, letters, flyers and signs. The templates shown here are from Microsoft Publisher.
25 Jigs, moulds, formers and templates
26 Product packaging Many graphic products are related to packaging. Companies package their products for a number of different reasons. To protect the product To preserve the product For easier transportation To advertise the product cardboard box Look how much packaging a simple cookie can create: individual plastic wrapper plastic tray large plastic wrapper bound in cellophane
27 Waste reduction Waste costs money – any materials that are used must be used in the most economical way. Designs need to be laid out so that the amount of waste created is minimal. Lets look at how we might layout the net for a cube. A layout like this is uneconomical. It wastes materials and only four cubes could be manufactured. Is there a better way?
28 Waste reduction By turning the shapes around, you can fit six on the sheet and reduce the wastage. A manufacturer could make 50% more cubes from the same card by laying them this way.
29 Waste reduction
30 Should cost impact design this much?Waste reduction Cost restrictions can sometimes limit our designs. If the product is on a tight budget, then the designer will have to make sure that their design will not be too expensive to make. E.g. rather than making boxes with round bases that create a lot of waste, square based boxes may be used. Should cost impact design this much?
31 Key points There are five main methods of production – one-off, batch, mass, continuous and just-in-time. The most appropriate method of production is determined by the number of items required. CAD and CAM systems are widely used in industry to improve the speed and quality of manufacture. Jigs, moulds, formers and templates are used to manufacture products faster and with greater accuracy. Manufacturers seek to cut costs by reducing waste in the production process. Key points 31 of 31 © Boardworks Ltd 2005